Manufacture of pile fabrics



April 16, 1957 M. BROOKES ETAL U 2,788,835

MANUFACTURE OF PILE FABRICS Filed Sept. 22, 1954 2 Sheeis-Sheet l 15- Z: 9 i 7 4@ a a 0 4mm FIG 3 F l G 4 u/Vfidfmfi Ma /47w 3:?00/(552 April 16, 1957 Filed Sept. 22, 1954 M. BROOKES ETAL MANUFACTURE OF FILE FABRICS 2 Sheets-Sheet 2 EP/(f.

United States Patent M UFACT R or urn FABRICS Mahath 'Brookes, Heaton, Bradford, and Eric Edgar SUD! derland, Bradford, England, assignors to Fabric Development Company, Limited, Addlngham, Yorkshire, England, .a conipany of Great Britain Application September 22,1954, Serial No. 457 ,706

Claimspriority, application Great Britain October 2, 19.53

11 Claims. (Cl. 154 1.1)

The invention relates to the manufacture of pile fabrics wherein the pile forming substance, e. g. yarn, threads, filaments, or sliver, are assembled in spaced parallel layers and consolidated with a solidifying medium to form a solid block which is cut transversely of the run-of the pile layers to form slabs which are backed with a plastic or other layer so that the tips of the pile are fixed in the backing, the consolidated or solidified medium being ultimately removed from the pile.

-Methods such as above referred to are described in specifications Nos. 2,516,559 and'2,49l,258.

The object of the invention is to enable a method of the characterabove referred to, .to be carried out more expeditiously and economically, and to facilitate the determining-ofthe-density of the pile fabric produced.

According to the invention in a method of manufacturing-pile fabric by assembling in a mould, pile forming substance in spaced parallel layers, consolidating them into a solid block by means of a solidifying medium, cutting lthe .block transversely of the run of the pile layerstoform slabs, exposing the pile tips, backing the slabs so 'that the exposed pile tips are fixed in the backing and ultimately removing the solidified medium from the pile, the steps or operations consisting in progressively layering solidifying medium and a layer of pile forming substance so that the combined layers are built up'progressively'to form the block.

In orderito increase the rate of output the progressive layeringis'efiected in: a long mould which is preferably adapted to permit of the long block so formed being out directly into slabs, or alternatively into sections' for convenient handling and ultimate cutting into slabs.

Continuous operations of the above nature involve the use of a considerable quantity of consolidating or solidifying medium. This medium which is preferably a solution of soluble alginate, such as ammonium alginate, containing 'an insoluble salt, such as di-calcium phosphate-which can form a gel for example by the addition of Fon'nalin. The'mixture increases in viscosity asthe setting .point is approached, and this is an item to be considered. in a method of manufacturing a pile fabric accordingto. the invention where the pouring or layering of the solidifying medium is extended. Therefore in order'itoavoid difiiculties in this connection and moreover to utilise the increase in viscosity under controlled conditions, instead of mixing the two reactants for storage ofthemixture inbulk, the two reactants are stored in'bulk' separately and are delivered under control to a mixing :vessel, the discharge of which to the mould is controlled, so that the relative quantities of the two reactants as well as the time during which they are being'rnixedand-discharged can be determined.

Th'efiprogressive assembling of layers 'of solidifying medium and pile formingsubs'tance is preferably elfected softhatthe latter is under tension and is pressed into the solidifying medium as this thickens prior to setting.

2,788,835 Patented Apr. 16, 1957 In order to obtain ,a ifinal homogeneous mass or solid block each successive layer of solidifying or consolidating medium is laid when the preceding layer has increased in viscosity sufficiently to support the next layer of medium and pile material, but has not fully set.

As explained in specification of U. S. Patent No. 2,491,258, when sliver is used as the pile forming substance it may be sized and dried to give it stability. However, under wet conditions as when layered in contact with a layer of solidifying medium, the dried soluble size would be liable to dissolve and sink in the medium before the latter has set sufliciently to support .the sliver. In order to avoid this difliculty in the method of manufacture according to the invention the sliver is in the first instance spray sized with a water soluble size and dried to give a paper-like handle, upon which is superimposed a suitable pattern of a water insoluble size similar in nature to the solidifying vmedium. When applied, this setting solution dissolves the soluble size in proximity to it, and thus embeds itself into the sliver tissue; it then thickens and sets giving a supporting framework to the sliver which is water-insoluble, as when in contact with the consolidating or solidifying medium in the mould.

This supporting pattern or framework is so disposed as to allow the free flow of consolidating medium through the layers of sliver without disturbing .the orientation of the layers of sliver and their component fibres. It is an. advantage, when sizing sliver, that no physical contact .is .made between the web of fibres and the size applying apparatus, such a method prevents the possi-. bility of licldng.or-dist-urbance of the web of'fibres. A mixing apparatus as hereinbeforedescribed, would be suitable for. continuously preparing such a solidifying insoluble size immediately prior to its application to the web.

The invention also comprises apparatus for carrying out the method of manufacturing a pile fabric such as above referred to.

In the accompanying drawings which are somewhat diagrammatic Figure 1 is a side-sectionalelevation and Figure 2 is an endelevat-ion illustrating one example of apparatus for preparing the consolidating or solidifying medium and progressively layering it and pile forming substancein a long mould;

Figure 3 is a plan of the layering-device;

Figures 4 and 5 arerespectively, a side elevation and a plan of a sectional mould;

Figure 6 schematically illustrates a long moulded bloc before being cut into sections;

Figure 7 illustrates one section of this block ready for cutting into slabs;

Figures 8, 9, 10 and 11 illustrate successive stages in the known subsequent treatment of slabs;

Figure 12 is a side elevation illustrating an alternative form of the apparatus for storing and mixing the solidifying medium; and

Figures 13 and 14 are sectional elevations of alternative forms of mixing vessel.

Referring to Figures 1, 2 and 3, two storage tanks 1 and 2 respectively, contain the bulk solutions whichvare to be mixed in a mixing vessel 3 to form the consolidating or solidifying medium.

The tank 1 contains'for example alginate solution with suspension of insoluble salt, and the other contains the setting medium, for example, Formalin solution.

The tanks 1 and 2 have-flexible delivery pipes 4 and 5 fitted with valves.6 and 7 respectively for cut off and controlling therate of discharge to the mixing vessel 3.

The mixing vessel 3 has a discharge nozzle 8 which may be fitted with a valve 9 for controlling the rate of discharge for layering the solidifying medium in the mould 10. The nozzle 8 is fan-shaped or splayed as shown in Figure 3 to spread the solidifying medium evenly.

By carefully setting the valves 6 and 7 the solutions from tanks 1 and 2 can pass into the mixing vessel 3 at controlled ratio according to the capacity of the vessel and the rate of discharge controlled by the valve 9, the retention or mixing time can be accurately determined to suit the demand for charging the mould 10 in which the pile forming substance is assembled. v

The tanks 1 and 2 and the mixing vessel 3 are'carried by a carriage 11 provided with wheels 12 running on a gantry 13, above the mould 10. The mould 10 can be of any desired length.

The layering device 14 is fitted with a bar 15 over which the pile forming substance 16 is led from the spool 17. The bar 15 is arranged just about level with or slightly below the side plates of the layering device 14 and thus acts as a doctor. The layering device 14 is supported from the carriage 11 by screw-threaded rods 18, actuated by a suitable lifting device for simplicity indicated by nuts 19 so that the depth of the layering device 14 can be accurately adjusted.

In operation assuming that the pile forming substance 16, for instance yarn, has been previously secured or anchored by suitable means (adhesion, tying or clipping) to a device for maintaining the previously determined spaced relationship, e. g. rod on the bottom at the right-hand side of the mould 10, and the rods 18 have lowered the layering device 14 so that the doctor bar 15 is at the required height above the bottom of the mould 24, the carriage 11 is moved along the gantry 13 in the direction of the arrow 21. Solidifying mixture discharging from the nozzle 8 beneath the lower edge of the doctor bar 15 is layered on the bottom of the mould 10. At the same time yarn from the spool 17 is layered on the layer of solidifying medium, being tensioned between the rod 20 and the spool 17 and being pressed by the doctor bar 15 into the layer of solidifying medium. When the carriage 11 has completed its travel to the left hand end of the mould 10, the supply of solidifying medium is cut off.

The layering device 14 is raised by the screws 18 a predetermined amount equal to the desired spacing of successive layers of yarn, and the carriage 11'is returned in the direction of the arrow 23. The raising of the screws by rotation of the nuts 19 may be effected auto matically by a trip device.

A fresh spool 17 wound with yarn is inserted in the layering device, the ends of the yarn being secured to a rod 20 placed on the previously formed combined layer of solidifying medium and yarn. The valves 6 and 7 are re-opened and the carirage 11 is again moved in the direction of the arrow 21 and a second layer of medium is layered on the first layer and a layer of yarn on the second layer.

The carriage 11 is reciprocated back and forth until the required number of layers has been built up progressively.

The yarn or other pile forming substance 16 is pressed into each viscous layer of solidifying medium.. It is essential in order to obtain a final homogeneous mass that each successive layer of consolidating medium i laid when the'preceding layer has increased in viscosity sufiicient to support the next layer of yarn, but has not fully set.. Each penultimate layer of this medium is very viscous prior to setting. When sufficient layers have been deposited to form a block extending throughout the mould and the block i sufficiently set or solid, it is cut transversely of the run of the yarn layers directly into slabs or alternatively into blocks of convenient size to facilitate removal and subsequent cutting into slabs,

When it is desired to cut the block directly into slabs a suitable conveyor 24 may form the bottom of the mould so enabling the block to be moved forward in predetermined increments according to the thickness of the slabs required towards a vertical cutting device fixed at one end 41 of the mould.

Alternatively in order to facilitate the removal of the blocks the mould 10 may be in detachable sections 25 as indicated in Figures 4 and 5.

The joints between the sections are packed with detachable gaskets 26, which when removed, permit the insertion of a'knife. In Figure 6' a block 27 is indicated cut along the lines 28 into smaller blocks 29. In Figure 7 a block 29 is indicated ready for cutting transversely along the lines 30 into slabs 31 Figure 8.

These slabs are first operated in known manner, for instance, as explained in specifications of U. S. Patents Nos. 2,516,559 and 2,491,258, to remove some of the solidifying medium to expose the pile tip 32, Figure 9, to which a backing 33 is applied, Figure 10, after which the solidifying medium is removed from the pile, Fig ure 11.

When a pattern is required in the pile fabric to be manufactured, the spools 17, Figure 1, can be wound with coloured yarns or sliver strands in a similar manner to that adopted with the spools of an Axminster type loom, each spool being prepared with selected colours representing one pick in the repeat of the pattern to be produced.

The carriage 11 may be propelled manually or by power. 7

Various means for controlling the discharge of solutions from the tanks 1 and 2 may be adopted, for example, instead of valves 6, 7 and 8 gear pumps or other pumps 34, 35 and 36 may be used as indicated in Fig ure 12.

The mixing in the mixing vessel 3 can be effected by any usual mixing means, for instance by arranging nozzles 37 and 38, Figure 13, from the valves 6 and 7 to co-operate to form turbulence, with or without the assistance of baffles 39; or rotary mixing propellers 40, Figure 14, may be used.

While the method of layering; the pile forming substance in a long mould as above described may only need rods 20 at the commencing end to anchor the substance and facilitate its being laid under tension, the spacing between adjacent layers of pile forming substance being determined by the layers of solidifyingmateria], the use of spacing elements as described in the before-mentioned specifications is not precluded.

We claim:

1. In a method of manufacturing pile fabric by assembling pile forming substance in spaced parallel layers in a mould and consolidating said layers with a solidifying medium into a solid block which is cut transversely of the run of the pile layers to form slabs and the ends of the pile on one side of the slabs are exposed and fixed to a backing layer after which the solidified medium is removed fromthe pile, the improvement comprising the steps of progressively layering solidifying medium in the mould, progressively layering pile forming substance in the mould immediately following the application of the solidifying medium, and pressing said pile forming substance into said solidifying medium and the layers of solidifying medium and pile forming substance together so that the combined layers are built up progressively to form the block. 2. A method of manufacturing pile fabric according to claim .1 wherein the pile forming substance is placed under tension as it is pressed into the. solidifying medium.

3. A method of manufacturing a pile fabric according to claim 1 wherein each successive layer of solidifying medium is laid when the preceding layerhas increased in viscosity sufiicient to support the next layer of pile forming substance but has not fully set. I

4. A method .Of manufacturing pile fabric according to claim 1 wherein the pile forming substance is sliver and said method includes the steps for pretreating the sliver with a water soluble size, drying the treated sliver and then selectively treating the sliver with a water insoluble size which dissolves the water soluble size that is contacted by it.

5. In a method of manufacturing pile fabrics wherein the pile forming substance is assembled in parallel layers in a mould and consolidated with a solidifiable medium to form a solid block which is cut transversely of the run of the pile layers to form slabs and the ends of the pile on one side of the slabs are exposed and fixed to a backing layer after which the solidified medium is removed from the pile, the improvement comprising the steps of progressively layering solidifiable medium and pile forming substance in the mould to form a block by progressively depositing a layer of the pile forming substance in the mould, delivering solidifiable medium in front of said pile forming substance as it is deposited, and pressing the pile forming substance into the mould as it is deposited for determining the thickness of the succeeding layer of solidifiable substance and the spacing between adjacent layers of pile forming substance.

6. A method of manufacturing a pile fabric as specified in claim 5 comprising mixing controlled quantities of solidifying medium forming reagents and immediately delivering the resultant mixture to the mould.

7. A method of manufacturing a pile fabric as specified in claim 5 comprising mixing controlled quantities of solidifying medium forming reactants, immediately delivering the resultant mixture to the mould, and laying the successive layer of pile forming substance after each layer of solidifiable medium increases in viscosity without fully setting.

8. A method of manufacturing a pile fabric as specified in claim 5 wherein the solidifiable medium and the pile forming substance is layered in a long mould having a removable end, and includes the steps of ejecting the formed block intermittently through said end and cutting the block transversely to form slabs.

9. A method of manufacturing a pile fabric as specified in claim 5 comprising the steps of subdividing said block into shorter blocks and cutting said shorter blocks into slabs.

10. Apparatus for moulding a block of layered solidifiable medium and pile forming substance, comprising a mould, a layering device within said mould comprising a transverse doctor bar, means for supporting a spool of pile forming substance to be passed around said bar, means for delivering solidifiable medium in front of said bar, rails above said mould, a carriage movable on said rails longitudinally of said mould, and means on said carriage and adjustably traversing said bar along said mould at the required height in said mould.

11. Apparatus for moulding a block of layered solidifiable medium and pile forming substance, comprising a mould, a layering device within said mould and comprising a transverse doctor bar, means for supporting a spool of pile forming substance to be passed around said bar, a mixing vessel for solidifiable medium, said vessel being fitted with a controlling valve and a nozzle for delivering solidifiable medium in front of said bar, rails above said mould, a reciprocatory carriage on said rails, said carriage supporting separate tanks for storing the reactants of solidifiable mixture for supplying said mixing vessel, and means on said carriage and adjustably supporting said layering device at successively varied heights in said mould.

References Cited in the file of this patent UNITED STATES PATENTS 2,491,258 Fuhrhop et al Dec. 13, 1949 2,516,559 Fuhrhop et al. July 25, 1950 592,602 Saks Apr. 15, 1952 

